Polyphthalatecarbonate membranes for aromatics/saturates separation

ABSTRACT

The present invention describes a method for separating mixtures of aromatics and non-aromatics into aromatic-enriched and non-aromatic-enriched streams by contacting the mixture with one side of a polyphthalate-carbonate membrane and selectively permeating the aromatic components of the mixture through the membrane.

The use of membranes to separate aromatics from saturates has long been pursued by the scientific and industrial community and is the subject of numerous patents.

U.S. Pat. No. 3,370,102 describes a general process for separating a feed into a permeate stream and a retentate stream and utilizes a sweep liquid to remove the permeate from the face of the membrane to thereby maintain the concentration gradient driving force. The process can be used to separate a wide variety of mixtures including various petroleum fractions, naphthas, oils, hydrocarbon mixtures. Expressly recited is the separation of aromatics from kerosene.

U.S. Pat. No. 2,958,656 teaches the separation of hydrocarbons by type, i.e., aromatic, unsaturated, saturated, by permeating a portion of the mixture through a non-porous cellulose ether membrane and removing permeate from the permeate side of the membrane using a sweep gas or liquid. Feeds include hydrocarbon mixtures, e.g., naphtha (including virgin naphtha, naphtha from thermal or catalytic cracking, etc.).

U.S. Pat. No. 2,930,754 teaches a method for separating hydrocarbons, e.g., aromatic and/or olefins from gasoline boiling range mixtures, by the selective permeation of the aromatic through certain non-porous cellulose ester membranes. The permeated hydrocarbons are continuously removed from the permeate zone using a sweep gas or liquid.

U.S. Pat. No. 4,115,465 teaches the use of polyurethane membranes to selectively separate aromatics from saturates via pervaporation.

The present invention relates to a process for the separation of aromatics from saturates.

Compared to distillation, membrane permeation can lead to considerable energy savings. A membrane can separate a mixture of aromatics and saturates, e.g., a heavy cat naphtha, into a high-octane, mainly aromatic permeate and a high-cetane, mainly saturated retentate. Both permeate and retentate are more valuable than the starting heavy cat naphtha.

SUMMARY OF THE INVENTION

The present invention is a method for separating mixtures of aromatics and non-aromatics into aromatic-enriched and non-aromatic-enriched streams by contacting the aromatics/non-aromatics mixture with one side of a polyphthalatecarbonate membrane, and selectively permeating the aromatic components of the mixture through the membrane. Both crosslinked and uncrosslinked polyphthalatecarbonate membranes can be used for the aromatics/non-aromatics separation.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is a method for the separation of aromatics from saturates using crosslinked and uncrosslinked polyphthalatecarbonate membranes. Polyphthalatecarbonates are commercially available. Examples are General Electric's PPC 4501 and PPC 4701; Mobay's APEC DP 9-9308 and APEC DP 9-9310. They are polyesters of Bisphenol A (4,4'-isopropylidenebiphenol) with variable proportions of carbonic, isophthalic and terephthalic acids.

In the present invention, membranes are used to separate a mixture of aromatics and non-aromatics into an aromatic-enriched fraction and a non-aromatic-enriched fraction.

The membranes are useful for the separation of aromatics from saturates in petroleum and chemical streams and are particularly useful for the separation of large substituted aromatics from saturates as are encountered in heavy cat naphtha streams. Other streams which are also suitable feed streams for aromatics from saturates separation are intermediate cat naphtha streams boiling at 93°-160° C, light aromatics content streams boiling in the C₅ -150° C. range, light catalytic cycle oil boiling in the 200°-345° C. range as well as streams in chemical plants which contain recoverable quantities of benzene, toluene, xylenes (BTX) or other aromatics in combination with saturates. The separation techniques which may successfully employ the membrane of the present invention include perstraction and pervaporation.

Perstraction involves the selective dissolution of particular components contained in a mixture into the membrane, the diffusion of those components through the membrane and the removal of the diffused components from the downstream side of the membrane by the use of a liquid sweep stream. In the perstractive separation of aromatics from saturates in petroleum or chemical streams, the aromatic molecules present in the feedstream dissolve into the membrane film due to similarities between the membrane solubility parameter and those of the aromatic species in the feed. The aromatics then permeate (diffuse) through the membrane and are swept away by a sweep liquid which is low in aromatics content. This keeps the concentration of aromatics at the permeate side of the membrane film low and maintains the concentration gradient which is responsible for the permeation of the aromatics through the membrane.

The sweep liquid is low in aromatics content so as not to itself decrease the concentration gradient. The sweep liquid is preferably a saturated hydrocarbon liquid with a boiling point much lower or much higher than that of the permeated aromatics. This is to facilitate separation, as by simple distillation. Suitable sweep liquids, therefore, would include, for example, C₃ to C₆ saturated hydrocarbons and lube basestocks (C₁₅ -C₂₀).

The perstraction process is run at any convenient temperature, preferably as low as possible.

The choice of pressure is not critical since the perstraction process is not dependent on pressure, but on the ability of the aromatic components in the feed to dissolve into and migrate through the membrane under a concentration driving force. Consequently, any convenient pressure may be employed, the lower the better to avoid undesirable compaction, if the membrane is supported on a porous backing, or rupture of the membrane, if it is not.

If C₃ and C₄ sweep liquids are used at 25° C. or above in liquid state, the pressure must be increased to keep them in the liquid phase.

Pervaporation, by comparison, is run at generally higher temperatures than perstraction and relies on vacuum on the permeate side to evaporate the permeate from the surface of the membrane and maintain the concentration gradient driving force which drives the separation process. As in perstraction, the aromatic molecules present in the feed dissolve into the membrane film, migrate through said film and emerge on the permeate side under the influence of a concentration gradient. Pervaporative separation of aromatics from saturates can be performed at a temperature of about 25° C. for the separation of benzene from hexane but for separation of heavier aromatic/saturate mixtures, such as heavy cat naphtha, higher temperatures of at least 80° C and higher, preferably at least 100° C. and higher, more preferably 120° C. and higher should be used. Temperatures of about 190.C have been successfully used with crosslinked polyphthalatecarbonate membranes of the present invention, the maximum upper limit being that temperature at which the membrane is physically damaged. Vacuum on the order of 1-50 mm Hg is pulled on the permeate side. The vacuum stream containing the permeate is cooled to condense out the highly aromatic permeate Condensation temperature should be below the dew point of the permeate at a given vacuum level.

The membrane itself may be in any convenient form utilizing any convenient module design. Thus, sheets of membrane material may be used in spiral wound or plate and frame permeation cell modules. Tubes and hollow fibers of membrane may be used in bundled configurations with either the feed or the sweep liquid (or vacuum) in the internal space of the tube or fiber; the other material obviously being on the other side.

When the membrane is used in a hollow fiber configuration with the feed introduced on the exterior side of the fiber, the sweep liquid flows on the inside of the hollow fiber to sweep away the permeated highly aromatic species, thereby maintaining the desired concentration gradient. The sweep liquid, along with the aromatics contained therein, is passed to separation means, typically distillation means, however, if a sweep liquid of low enough molecular weight is used, such as liquefied propane or butane, the sweep liquid can be permitted to simply evaporate, the liquid aromatics being recovered and the gaseous propane or butane (for example) being recovered and reliquefied by application of pressure or lowering of temperature.

Crosslinked polyphthalatecarbonate films can be obtained by preparing a solution in a suitable solvent, e.g., chloroform, casting on a glass plate or a porous support, adjusting the thickness with a casting knife and drying the membrane first at room temperature, then at high temperatures, e.g., 120° C. and 230° C., etc., possibly in the presence of an additive, e.g., cupric acetylacetonate. Uncrosslinked polyphthalatecarbonate films can be prepared in the same way except no crosslinking additive is used and drying temperatures are not higher than about 120° C.

The present invention will be better understood by reference to the following examples which are offered by way of illustration and not limitation.

In the following examples, membranes are used to separate aromatics from saturates in a pervaporation apparatus. The pervaporation apparatus is a cell, separated into two compartments by a porous metal plate, on which the membrane is supported. During a pervaporation experiment the aromatics/saturates mixture is circulated through the upper compartment at the desired temperature. The lower compartment is kept at reduced pressure. The permeate is collected in a trap, cooled with dry ice-acetone or dry iceisopropanol and periodically analyzed by gas chromatography. The following examples illustrate the invention.

EXAMPLE 1

20.25 g of a polyphthalatecarbonate containing 42 moles of isophthalic acid, 4 moles of terephthalic acid and 54 moles of carbonic acid for 100 moles of Bisphenol A was dissolved in 100 ml of chloroform at room temperature. When dissolution was complete, 0.187 g of cupric acetylacetonate was added. About 50 ml of chloroform was allowed to evaporate in order to have a sufficiently thick solution for casting. After centrifugation, four membranes were cast on glass plates under nitrogen. After two days the membranes were removed by immersing the glass plates in warm water. After drying, square pieces were cut and the sides were clamped between stainless-steel holders which lay on a small table covered with Gore-tex (porous Teflon) sheet. The distance between the membrane and the Gore-tex sheet was about 1/2 inch. Weights attached to the clamp kept the membranes suspended above the Gore-tex sheets. The membranes were crosslinked by heating them in an oven under the following conditions.

    ______________________________________                                         120° C.                                                                               17 hours     in nitrogen                                         160° C.                                                                               24 hours     in air                                              230° C.                                                                                5 hours     in air                                              ______________________________________                                    

The resulting membranes were insoluble in chloroform, i.e., crosslinked.

One of the membranes was used in the pervaporation apparatus described above for the separation of a mixture containing 10 wt% toluene, 40% p-xylene, 20% isooctane and 30% n-octane. The following table gives the results.

    ______________________________________                                                             Aromatics/                                                 T    Toluene/n-Octane                                                                              Saturates Normalized Flux                                  (°C.)                                                                        Selectivity    Selectivity                                                                              (Kg · μM/M.sup.2 ·          ______________________________________                                                                       D)                                               150  6.1            9         500                                              170  5.2            7.5       950                                              190  4.9            6         2000                                             ______________________________________                                    

EXAMPLE 2

40 g of polyphthalatecarbonate containing 71 moles of isophthalic acid, 7 moles of terephthalic acid and 21 moles of carbonic acid per 100 moles of Bisphenol A was dissolved in 240 g of chloroform. When dissolution was complete, 0.38 g of cupric acetylacetonate was added. Four membranes were cast on glass plates under nitrogen. After drying, the membranes were suspended above Gore-tex sheets as described in Example 1. The heating cycle was:

    ______________________________________                                         120° C.                                                                               17 hours     in nitrogen                                         160° C.                                                                               24 hours     in air                                              190° C.                                                                               24 hours     in air                                              230° C.                                                                                5 hours     in air                                              ______________________________________                                    

At the end the membranes were flexible and insoluble in CHCl₃, i.e., crosslinked. 

What is claimed is:
 1. A method for separating mixtures of aromatics and non-aromatics into aromatic-enriched and non-aromatic-enriched streams comprising:(a) contacting said aromatics/non-aromatics mixture with one side of a polyphthalatecarbonate membrane, and (b) selectively permeating the aromatic components of the mixture through the membrane.
 2. The method of claim 1 where said membrane is obtained by casting a polyphthalatecarbonate solution and crosslinking the membrane thermally in the presence of air or oxygen.
 3. The method of claim 2 wherein crosslinking is effected in the presence of cupric acetylacetonate.
 4. The method of claim 1 wherein the polyphthalatecarbonate is aromatic.
 5. The method of claim 1 wherein the polyphthalatecarbonate is derived from Bisphenol A.
 6. The method of claim 1 wherein the separation is performed under pervaporation conditions.
 7. The method of claim 1 wherein the separation is performed under perstraction conditions.
 8. The method of claim 1 wherein the aromatics/non-aromatics mixtures are selected from heavy catalytic naphtha streams, intermediate catalytic naphtha streams, light aromatics streams boiling in the C₅ -150° C. range and light catalytic cycle oils boiling in the 200°-345° C. range. 